SI E 1001 Replacement 247-7829 Electronic Pilot Valve

SPECIAL INSTRUCTION
Reference: SI E 1001
June 15, 2010
Attention: This notice is being issued to advise you of new information for certain
Caterpillar (“CAT”) Telehandlers that were manufactured by JLG Industries,
Inc. (“JLG”).
TITLE:
Procedure to Replace the Rear Hydraulic Electronic Pilot Valve GP.
APPLICABLE PRODUCTS:
Model Serial Number Range

TH220B TBF00100 & After
TH330B TBG00100 & After
TH360B TBH00100 & After
TH560B TBP00100 & After
TH580B TBJ00100 & After
INTRODUCTION:
This special instruction will provide information for replacing the Rear Implement 247-7829
Electronic Pilot Valve Gp on B-Series Telehandler Machines
PROCEDURE:
In order to complete this rework, a number of steps have to be followed as described in this
Special instruction.
IMPORTANT SAFETY INFORMATION
Work safely. Most accidents that involve product operation, maintenance, and repair are caused
by failure to observe basic safety rules or precautions.
An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs.
A person must be alert to potential hazards. This person should also have the necessary
training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these
hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all
inclusive. If a tool, a procedure, a work method or operating technique that is not specifically
recommended by Caterpillar is used, you must ensure that it is safe for you and for other people
to use. You should ensure that the product will not be damaged or the product will be made
unsafe by the operation, lubrication, maintenance or the repair procedures that are used.
PARTS NEEDED:
The following part must be ordered to accomplish this update:
Part
Description
Quantity Number
Table 1
*** Required Master Software ***
1 356-7326 Machine Software GP

NOTE: Always flash the master software that is in Table 1 or any newer versions of this
software.
Part
Description
Quantity Number
Table 2
*** Parts that are required to replace the Rear Implement 247-7829
Electronic Pilot Valve GP ***
1 329-2576 Electronic Control Module
4 179-3543 Control Manifold and Solenoid Gp
4 5D-6543 O-Ring Seals
12 5F-9144 O-Ring Seals
1 263-9558 Control Harness As
8 155-0576 Isolation Mounts
4 9N-0869 Hard Washers
4 6I-1418 Spacers
4 8T-6912 Bolts
16 095-0642 Bolts
10 3S-2093 Cable Straps
2 231-2295 Connector Plug As
1 176-9299 Receptacle Kit
3 8T-8737 Seal Plugs
1 356-3664 Machine Software Gp
1 Rear Cover Refer to Table 3 for the correct rear cover.
Telehandler Part
Description
Model Number
Table 3
*** Selection table for Rear Cover ***
TH220B 338-0820 Cover As
INSTRUCTIONS
Before service work is begun, park the machine on a hard level surface. Block the wheels of the
machine so unexpected movement will not occur. Unexpected movement of the machine can
cause personal injury or death.
ECM 2 Connector
Address Out 2
CAN A + 3
+10V 4 PHS ECM 2
GND 5
CAN A- S
Address In 7
+Battery 8
ECM 1 Connector
Address Out 2
CAN A + 3
PHS ECM 1
+10V 4
GND 5
CAN A- S
Address In 7
+Battery 8
Illustration 1 g02107833
Original schematic for the rear Programmable Hydraulic System (PHS) 3
Electrical Schematic of the new Rear Programmable Hydraulic System (PHS)
Note: The pictures that are shown are taken from a TH580B machine. These instructions are still valid for other Telehandler models even though the pictures may be different from the
machine model that is being updated.
4
Rear cover that is still on the machine
Rear cover that was removed from the machine
1. Remove the rear cover that is located on the back left side of the machine by unscrewing the two bolts that secure the cover to the machine. Discard the cover. This cover exposes
the PHS for the rear implement. Refer to Illustration 3 and Illustration 4. Carefully note
5 that the top connector (2) connects to ECM 2 and that the bottom connector (1) connects to
ECM 1. Marking the connectors is important. These connections will need to be connected to specific connectors on the other end of the harness.
2. Unplug the two connectors from the PHS. Replace both connectors with a 231-2295 Connector Plug As .
Note: The old connectors may be the same style as the new connectors. Replace the old connectors even in this event.
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3. Prepare the four 179-3543 Control Manifold and Solenoid Gp valves by placing one 5D-6543 O-Ring Seal and three 5F-9144 O-Ring Seals on each valve.
Note: Lubricate the O-rings with clean hydraulic oil so the O-rings will stick to the valve.
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the engine has
been stopped. Serious injury can be caused if this pressure is not released before
any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before removing
any components or lines. Remove the oil filler cap only when the engine is
stopped, and the filler cap is cool enough to touch with your bare hand.
----------------------
7
Cylinders equipped with load control valves can remain pressurized, even with
hoses removed.
Failure to relieve pressure before removing a load control valve or disassembling

a cylinder can result in personal injury or death.
Ensure all pressure is relieved before removing a load control valve or

disassembling a cylinder.
----------------------
NOTICE
Care must be taken to ensure that fluids are contained during performance of
inspection, maintenance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers before opening any
compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Note: Refer to Testing and Adjusting, RENR5188, "Hydraulic System Pressure - Release" before starting Step 4 on the TH360B, TH460B, and the TH560B Telehandlers.
Note: Refer to Testing and Adjusting, RENR7756, "Hydraulic System Pressure - Release" before starting Step 4 on the TH580BTelehandlers.
8
4. Remove the bolts (3) that connect the PHS to the valve stack. Eight mounting bolts connect the PHS to the valve stack. Four are shown in Illustration 7 and the other four bolts are
on the bottom side in the same position.
Note: Before removing the PHS, have something on hand in order to collect the hydraulic oil.
9
5. The PHS is removed in Illustration 8. Clean any debris before installing the new solenoid valves.
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6. Use four new 095-0642 Bolts in order to mount each solenoid valve to the valve manifold. Refer to Illustration 10. Refer to, 1E0279, "Tightening – Fasteners and Threaded Parts"
for the correct torque requirements.
ECM mounting hardware that is correctly installed on the ECM 11
7. Install the mounting hardware for the 329-2576 Electronic Control Module onto the new ECM. The mounting hardware for the ECM requires four 8T-6912 Bolts (4), four 9N-0869
Hard Washers (5), eight 155-0576 Isolation Mounts (6), and four 6I-1418 Spacers (7). Illustration 11 and Illustration 12 shows the order that the hardware will go together.
8. Mount the ECM to the new rear cover for the ECM. The new rear cover will be determined by using Table 3. Some machines allow the rear covers to be bolted on one way while
other machines allow the rear cover to be bolted on two different ways by rotating the cover 180 degrees.
Note: Make sure that the part number for the ECM is on the bottom of the cover when the cover is bolted back to the machine.
9. Attach the 263-9558 Control Harness As to the ECM and set the harness aside.
12
10. Locate the receptacle resistor for the CAN in the original harness. The connector for the resistor should look like the one in Illustration 14. Replace the receptacle resistor for the
CAN with the 176-9299 Receptacle Kit and three 8T-8737 Seal Plugs .
13
11. The 263-9558 Control Harness As that is connected to the ECM has two 8-pin connectors at the other end of the bulkhead. These two connectors will mate with the two connectors
from Step 1. The original bottom connector (1) for ECM 1 needs to connect with the 8-pin connector that has three wires. The original top connector (2) for ECM 2 needs to connect
with the 8-pin connector that has five wires.
(8) Wire (K760-PU) and wire (K761-GR)
(9) Wire (K762-BL) and wire (K763-GY)
(10) Wire (T973-WH) and wire (T974-BR)
(11) Wire (T975-PK) and wire (T978-GY)
(12) Wire (T971-OR) and wire (T972-GN)
(13) Wire (T969-YL) and wire (T970-GY)
(14) Wire (E891-WH) and wire (E892-PK)
(15) Wire (E893-BR) and wire (E894-OR)
12. Connect the 263-9558 Control Harness As to the solenoid drivers in the following order from left to right:
❍ Wire (K760-PU) and wire (K761-GR) are in connector (8) .
❍ Wire (K762-BL) and wire (K763-GY) are in connector (9) .

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❍ Wire (T973-WH) and wire (T974-BR) are in connector (10) .
❍ Wire (T975-PK) and wire (T978-GY) are in connector (11) .
❍ Wire (T971-OR) and wire (T972-GN) are in connector (12) .
❍ Wire (T969-YL) and wire (T970-GY) are in connector (13) .
❍ Wire (E891-WH) and wire (E892-PK) are in connector (14) .
❍ Wire (E893-BR) and wire (E894-OR) are in connector (15) .
13. Route the 263-9558 Control Harness As inside the machine. Use a 3S-2093 Cable Strap to secure the harness to a machine link. Refer to Illustration 17. Some models might not
have a machine link. Machines that do not have a machine link will use 3S-2093 Cable Straps to secure the harness.
Note: Never strap a harness to any hydraulic hose that flexes during implement movement.
15
14. Use a 3S-2093 Cable Strap to attach the resistor receptacle for the CAN to the harness.
Service port
16
15. Use a 3S-2093 Cable Strap to attach the service port to the harness.
16. Extra 3S-2093 Cable Straps have been provided in order to better package the harness inside the machine. Install the cover that came with the harness on the harness at the ECM
connection.
17. This step completes the replacement of the ECM valve group for the rear implement. Now flash the new software in the rear hydraulic ECM. Refer to ""Instructions for Flashing
Software on the Rear Hydraulic ECM" ".
Instructions for Flashing Software on the Rear Hydraulic ECM

Flash the new software by using the service port that is located on the 263-9558 Control Harness As . Power up the machine before connecting to the service port. Do not run the machine
at this time.
17
1. Connect Caterpillar Electronic Technician (Cat ET) to the ECM. Select the "Utilities" tab from the top menu and then choose "WinFlash".
18
2. Wait for "WinFlash" in order to connect to the ECM.
19
3. Select the "Implement Control" ECM.
20
4. From the "File Information" quadrant, select "Browse". Then select the 356-3664 Machine Software Gp flash file.
21
5. Select the "Begin Flash" option.
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6. Once the flash is complete, return to the Cat ET screen. Cycle the power for the machine after the flash is complete.
Instructions for Updating the Master Implement ECM Software

1. Power up the machine. Then connect Cat ET to the main service port that is located just below the left side of the seat.
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2. Once Cat ET has connected, select the "Main Control ECM".
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3. Select the "Utilities" tab from the top menu. Then choose "WinFlash".
25
4. Select "Machine Control Module".
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5. From the "File Information" quadrant, select "Browse". Then select the Machine Software Gp flash file. Go to SIS web to check for the latest version.
27
6. Once the flash is complete, return to the Cat ET screen. When the flash is complete, cycle the power.
Note: After flashing all the required software, calibrate all of the implement levers and the respective solenoids.
Note: After the calibration, operate the machine in order to verify correct responses. If the movement of the machine implement seems slow, then use Cat ET and change the max current
for each function accordingly. Refer to ""Instructions for Changing Max Current Calibration Values" " in order to change the max current calibration values for the implement speed.
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Instructions for Changing Max Current Calibration Values
1. Within Cat ET, select the "Service" tab from the top menu. Then choose "Configuration".
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2. Select the "Machine Control ECM" that is shown on the left in Illustration 33. Then select "PHS Max Current Calibration Values " that is shown on the right of Illustration 33.
3. Increase the maximum values for the PHS current. The PHS current values are the top six values that are under "PHS Max Current Calibration Values ". The increase in PHS
current will need to be some random amount below 1.7 Amperes. Test the implement in order to verify that the implement speeds have increased. Repeat this procedure until an
acceptable response is achieved. The maximum current that can be set is 1.7 Amperes. Cycle the key after each change in PHS current value.
The procedure to replace the 247-7829 Electronic Pilot Valve Gp for the rear Implement ECM is complete.
Diagnostic Procedures
Diagnostic Code MID 039-CID 1138 - FMI 03
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This diagnostic is associated with the Boom Retract Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 03" means that the ECM has determined that the voltage is above
normal.
Possible causes for the MID 039-CID 1138 - FMI 03 diagnostic code are listed below.
● The energized side of circuit (E893-BR) is shorted to the battery.
● The return side of the circuit (E894-OR) is shorted to the battery.
Note: The following test procedure may create other diagnostic codes. Ignore these codes and focus on the original diagnostic code. Ensure that the diagnostic code CID 1138 FMI 03 is
active before performing this procedure.
Note: Use a 146-4080 Digital Multimeter Gp or a similar multimeter for the measurements in this procedure.
System Response
● All functions are disabled.
Test Step 1
1. Ensure that the key for the machine is off.
2. Unplug the rear hydraulic ECM and the Boom Retract Solenoid.
3. Measure continuity between X1 and all power sources. 31

Expected Test Results From Test Step 1
● If the resistance is greater than 5k OHMS or equal to 5k OHMS, then go to ""Test Step 2" ".
● If the resistance is less than 5k OHMS, then wire (E893-BR) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 2
1. Measure the continuity between Y1 and all power sources.
● If the resistance is less than 5k OHMS, then wire (E894-OR) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 3
1. Inspect the contacts of the harness connectors and clean the harness connectors.
2. Reconnect all of the harness connectors.
3. Turn the disconnect switch and the key start switch to the ON position.
4. Operate the machine.
5. Check the status of the CID 1138 FMI 03 diagnostic code.
● The CID 1138 FMI 03 diagnostic code is no longer active. The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was
disconnected and reconnected.
● The CID 1138 FMI 03 diagnostic code is still active. The ECM may have failed. It is unlikely that the ECM has failed. Repeat this procedure again.
32
Diagnostic Code MID 039-CID 1138 - FMI 05 is associated with the Boom Retract Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 05" means that the ECM has
determined that an open or a short to ground exists in the circuit for the Boom Retract Solenoid.
● The power side of circuit (E893-BR) is open.
● The power side of circuit (E893-BR) is shorted to ground.
● The return side of the circuit (E894-OR) is open.
● The return side of the circuit (E894-OR) is shorted to ground.
● The Boom Retract Solenoid is faulty. The solenoid could have an open or a short to ground internally.
Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and focus on the original diagnostic code. Ensure that the diagnostic code CID 1138
FMI 05 is active before performing this procedure.
System Response
● The boom extend functions and boom retract functions will not work properly.
33
Test Step 1
2. Unplug the connector for the Boom Retract Solenoid.
3. Measure continuity between X1 and Y1.
● If the resistance is 2.5 OHMS plus or minus .5 OHMS, go to ""Test Step 5" ".
● If the resistance is not in the range, go to ""Test Step 2" ".
Test Step 2
1. Disconnect the Boom Retract Solenoid.
2. Place a suitable jumper wire between X2 and Y2.
3. Measure the continuity between X1 and Y1.
● If the resistance of the Boom Retract Solenoid is less than or equal to 5 OHMS, then the solenoid has failed. Repeat ""Test Step 2" " in order to verify the solenoid failure. After
verification, replace the Boom Retract Solenoid and verify that the new solenoid fixes the problem.
● If the resistance is greater than 5 OHMS, then go to ""Test Step 3" ".
Test Step 3
1. Remove the jumper wire that is between X2 and Y2.
2. Measure the continuity between X1 and X2.
● If the resistance of the Boom Retract Solenoid is less than or equal to 5 OHMS, then go to ""Test Step 4" ".
● If the resistance is greater than 5 OHMS, then wire (E893-BR) is open. Repair the circuit or replace the jumper harness.
Test Step 4
1. Verify that the jumper wire between X2 and Y2 is removed.
2. Measure continuity between Y1 and Y2. 34

● If the resistance is greater than 5 OHMS, then wire (E894-OR) is open. Repair the circuit or replace the jumper harness.
● If the resistance is less than or equal to 5 OHMS, then, the jumper harness is correct. Go to ""Test Step 7" ".
Test Step 5
2. Measure continuity between X1 and all ground sources.
a. Measure continuity from X1 to the ground pins on the Rear Hydraulic ECM.
b. Measure continuity between X1 and Y1 on the Rear Hydraulic ECM.
c. Measure continuity between X1 and the frame ground.
Expected Results From Test Step 5
● If the resistance is less than 5 OHMS then, Wire (E893-BR) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 6
2. Measure continuity between Y1 and all ground sources.
a. Measure continuity from Y1 to the ground pins on the Rear Hydraulic ECM.
b. Measure continuity between Y1 and X1 on the Rear Hydraulic ECM.
c. Measure continuity between Y1 and the frame ground.
● If the resistance is greater than 5k OHMS, or equal to 5k OHMS, then go to ""Test Step 7" ".
● If the resistance is less than 5k OHMS, wire (E894-OR) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 7
1. Inspect the contacts of the harness connectors and clean the harness connectors. 35
Diagnostic Code MID 039-CID 1193 - FMI 03 is associated with the Boom Extend Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 03" means that the ECM has
determined that the voltage is above normal.
● The energized side of circuit (E891-WH) is shorted to the battery. 36

● The return side of the circuit (E892-PK) is shorted to the battery.
System Response
Test Step 1
2. Unplug the rear hydraulic ECM and the Boom Retract Solenoid.
3. Measure continuity between X1 and all power sources.
● If the resistance is less than 5k OHMS, then wire (E891-WH) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 2
● If the resistance is less than 5k OHMS, then wire (E892-PK) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 3
4. Operate the machine. 37

Diagnostic Code MID 039-CID 1193 - FMI 05 is associated with the Boom Extend Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 05" means that the ECM has
determined that an open or a short to ground exists in the circuit for the Boom Extend Solenoid.
● The power side of circuit (E891-WH) is open.
● The power side of circuit (E891-WH) is shorted to ground.
● The return side of the circuit (E892-PK) is open.
● The return side of the circuit (E892-PK) is shorted to ground. 38

● The Boom Extend Solenoid is faulty. The solenoid could have an open or a short to ground internally.
System Response
● The boom extend will not work properly, but the boom retract will still work.
Test Step 1
2. Unplug the connector for the Boom Extend Solenoid.
Test Step 2
1. Disconnect the Boom Extend Solenoid.
● If the resistance of the Boom Extend Solenoid is less than or equal to 5 OHMS, then the solenoid has failed. Repeat ""Test Step 2" " in order to verify the solenoid failure. After
verification, replace the Boom Extend Solenoid. Verify that the new solenoid fixes the problem.
Test Step 3
2. Measure the continuity between X1 and X2. 39

● If the resistance of the Boom Extend Solenoid is less than or equal to 5 OHMS, then go to ""Test Step 4" ".
● If the resistance is greater than 5 OHMS, then wire (E891-WH) is open. Repair the circuit or replace the jumper harness.
Test Step 4
2. Measure continuity between Y1 and Y2.
● If the resistance is greater than 5 OHMS, then wire (E892-PK) is open. Repair the circuit or replace the jumper harness.
● If the resistance is less than or equal to 5 OHMS, then the jumper harness is correct. Go to ""Test Step 7" ".
Test Step 5
● If the resistance is greater than 5 OHMS or equal to 5 OHMS, then go to ""Test Step 6" ".
● If the resistance is less than 5 OHMS, then wire (E891-WH) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 6
40
● If the resistance is less than 5k OHMS, wire (E892-PK) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 7
41
Diagnostic Code MID 039-CID 2240 - FMI 03 is associated with the Tilt Extend Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 03" means that the ECM has
Possible causes for the MID 039-CID 2240- FMI 03 diagnostic code are listed below.
● The energized side of circuit (T971-OR) is shorted to the battery.
● The return side of the circuit (T972-GN) is shorted to the battery.
System Response
Test Step 1
2. Unplug the rear hydraulic ECM and the Tilt Extend Solenoid.

● If the resistance is greater than 5k OHMS, or equal to 5k OHMS, then go to ""Test Step 2" ".
● If the resistance is less than 5k OHMS, then wire (T971-OR) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 2
● If the resistance is less than 5k OHMS, then wire (T972-GN) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 3
43
Diagnostic Code MID 039-CID 2240 - FMI 05 is associated with the Tilt Extend Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 05" means that the ECM has
determined that an open or a short to ground exists in the circuit for the Tilt Extend Solenoid.
● The power side of circuit (T971-OR) is open.
● The power side of circuit (T971-OR) is shorted to ground.
● The return side of the circuit (T972-GN) is open.
● The return side of the circuit (T972-GN) is shorted to ground.
● The Tilt Extend Solenoid is faulty. The solenoid could have an open or a short to ground internally.
System Response
● The functions of the fork rack and the fork dump will not work properly.
44
Test Step 1
2. Unplug the connector for the Tilt Extend Solenoid.
Test Step 2
1. Disconnect the Tilt Extend Solenoid.
● If the resistance of the Tilt Extend Solenoid is less than or equal to 5 OHMS, then the solenoid has failed. Repeat ""Test Step 2" " in order to verify the solenoid failure. After
verification, replace the Tilt Extend Solenoid and verify that the new solenoid fixes the problem.
Test Step 3
● If the resistance of the Tilt Extend Solenoid is less than or equal to 5 OHMS, then go to ""Test Step 4" ".
● If the resistance is greater than 5 OHMS, then wire (T971-OR) is open. Repair the circuit or replace the jumper harness.
Test Step 4

● If the resistance is greater than 5 OHMS, then wire (T972-GN) is open. Repair the circuit or replace the jumper harness.
Test Step 5
● If the resistance is less than 5 OHMS, then wire (T971-OR) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 6
● If the resistance is less than 5k OHMS, the wire (T972-GN) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 7
Diagnostic Code MID 039-CID 2241 - FMI 03 is associated with the Tilt Retract Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 03" means that the ECM has
● The energized side of circuit (T969-YL) is shorted to the battery. 47

● The return side of the circuit (T970-GY) is shorted to the battery.
System Response
Test Step 1
2. Unplug the rear hydraulic ECM and the Tilt Retract Solenoid.
● If the resistance is less than 5k OHMS, then wire (E893-BR) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 2
● If the resistance is less than 5k OHMS then wire (T970-GY) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 3

This diagnostic is associated with the Tilt Retract Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 05" means that the ECM has determined that an open or a short to
ground exists in the circuit for the Tilt Retract Solenoid.
● The power side of circuit (T969-YL) is open.
● The power side of circuit (T969-YL) is shorted to ground.
● The return side of the circuit (T970-GY) is open.
● The return side of the circuit (T970-GY) is shorted to ground. 49

● The Tilt Retract Solenoid is faulty. The solenoid could have an open or a short to ground internally.
System Response
● The function of the fork rack and the fork dump will not work properly.
Test Step 1
2. Unplug the connector for the Tilt Retract Solenoid.
● If the resistance is 2.5 OHMS plus or minus .5 OHMS go to ""Test Step 5" ".
● If the resistance is not in the range go to ""Test Step 2" ".
Test Step 2
1. Disconnect the Tilt Retract Solenoid.
● If the resistance of the Tilt Retract Solenoid is less than or equal to 5 OHMS, then the solenoid has failed. Repeat ""Test Step 2" " in order to verify the solenoid failure. After
verification, replace the Tilt Retract Solenoid and verify that the new solenoid fixes the problem.
Test Step 3

● If the resistance of the Tilt Retract Solenoid is less than or equal to 5 OHMS, then go to ""Test Step 4" ".
● If the resistance is greater than 5 OHMS, then wire (T969-YL) is open. Repair the circuit or replace the jumper harness.
Test Step 4
● If the resistance is greater than 5 OHMS, then wire (T970-GY) is open. Repair the circuit or replace the jumper harness.
Test Step 5
● If the resistance is greater than 5 OHMS or equal to 5 OHMS then go to ""Test Step 6" ".
● If the resistance is less than 5 OHMS then wire (T969-YL) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 6
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● If the resistance is less than 5k OHMS Wire (T970-GY) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 7
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This diagnostic is associated with the Auxiliary Open Retract Solenoid (Port B) that is controlled by the Rear Hydraulic ECM. The "FMI 03" means that the ECM has determined that the
voltage is above normal.
● The energized side of circuit (T973-WH) is shorted to the battery.
● The return side of the circuit (T974-BR) is shorted to the battery.
System Response
Test Step 1
2. Unplug the rear hydraulic ECM and the Auxiliary Open Retract Solenoid (Port B).

● If the resistance is less than 5k OHMS then wire (T973-WH) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 2
● If the resistance is less than 5k OHMS then wire (T974-BR) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 3
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This diagnostic is associated with the Auxiliary Close Extend Solenoid (Port A) that is controlled by the Rear Hydraulic ECM. The "FMI 05" means that the ECM has determined that an
open or a short to ground exists in the circuit for the Tilt Retract Solenoid.
● The power side of circuit (T973-WH) is open.
● The power side of circuit (T973-WH) is shorted to ground.
● The return side of the circuit (T974-BR) is open.
● The return side of the circuit (T974-BR) is shorted to ground.
● The Auxiliary Close Extend Solenoid (Port A) is faulty. The solenoid could have an open or a short to ground internally.
System Response
● The Auxiliary Close Extend Solenoid (Port A) and the Auxiliary Close Retract Solenoid (Port B) will not function properly.
55
Test Step 1
2. Unplug the connector for the Auxiliary Close Extend Solenoid (Port A).
Test Step 2
1. Disconnect the Auxiliary Close Extend Solenoid (Port A).
● If the resistance of the Auxiliary Close Extend Solenoid (Port A) is less than or equal to 5 OHMS, then the solenoid has failed. Repeat ""Test Step 2" " in order to verify the
solenoid failure. After verification, replace the Auxiliary Close Extend Solenoid (Port A) and verify that the new solenoid fixes the problem.
Test Step 3
● If the resistance of the Auxiliary Close Extend Solenoid (Port A) is less than or equal to 5 OHMS, then go to ""Test Step 4" ".
● If the resistance is greater than 5 OHMS, then wire (T973-WH) is open. Repair the circuit or replace the jumper harness.
Test Step 4

● If the resistance is greater than 5 OHMS, then wire (T974-BR) is open. Repair the circuit or replace the jumper harness.
Test Step 5
● If the resistance is less than 5 OHMS, then wire (T973-WH) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 6
● If the resistance is less than 5k OHMS Wire (T974-BR) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 7
This diagnostic is associated with the Auxiliary Open Retract Solenoid (Port B) that is controlled by the Rear Hydraulic ECM. The "FMI 03" means that the ECM has determined that the
voltage is above normal.
● The energized side of circuit (T975-PK) is shorted to the battery. 58

● The return side of the circuit (T978-GY) is shorted to the battery.
System Response
Test Step 1
2. Unplug the rear hydraulic ECM and the Auxiliary Open Retract Solenoid (Port B).
● If the resistance is less than 5k OHMS then wire (T975-PK) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 2
● If the resistance is less than 5k OHMS then wire (T978-GY) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 3

This diagnostic is associated with the Auxiliary Open Retract Solenoid (Port B) that is controlled by the Rear Hydraulic ECM. The "FMI 05" means that the ECM has determined that an
open or a short to ground exists in the circuit for the Auxiliary Open Retract Solenoid (Port B).
● The power side of circuit (T975-PK) is open.
● The power side of circuit (T975-PK) is shorted to ground.
● The return side of the circuit (T978-GY) is open.
● The return side of the circuit (T978-GY) is shorted to ground. 60

● The Auxiliary Open Retract Solenoid (Port B) is faulty. The solenoid could have an open or a short to ground internally.
System Response
● The Auxiliary Close Extend Solenoid (Port A) and the Auxiliary Open Retract Solenoid (Port B) will not function properly.
Test Step 1
2. Unplug the connector for the Auxiliary Open Retract Solenoid (Port B).
Test Step 2
1. Disconnect the Auxiliary Open Retract Solenoid (Port B).
● If the resistance of the Auxiliary Open Retract Solenoid (Port B) is less than or equal to 5 OHMS, then the solenoid has failed. Repeat ""Test Step 2" " in order to verify the solenoid
failure. After verification, replace the Auxiliary Open Retract Solenoid (Port B) and verify that the new solenoid fixes the problem.
Test Step 3

● If the resistance of the Auxiliary Open Retract Solenoid (Port B) is less than or equal to 5 OHMS, then go to ""Test Step 4" ".
● If the resistance is greater than 5 OHMS, then wire (T975-PK) is open. Repair the circuit or replace the jumper harness.
Test Step 4
● If the resistance is greater than 5 OHMS, then wire (T978-GY) is open. Repair the circuit or replace the jumper harness.
Test Step 5
● If the resistance is less than 5 OHMS, then wire (T975-PK) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 6
62
● If the resistance is less than 5k OHMS Wire (T978-GY) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 7
63
This diagnostic is associated with the Boom Telescope Extend Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 03" means that the ECM has determined that the voltage
is above normal.
● The energized side of circuit (K760-PU) is shorted to the battery.
● The return side of the circuit (K761-GN) is shorted to the battery.
System Response
Test Step 1
2. Unplug the rear hydraulic ECM and the Boom Telescope Extend Solenoid.

● If the resistance is less than 5k OHMS then wire (K760-PU) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 2
● If the resistance is less than 5k OHMS then wire (K761-GN) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 3
65
This diagnostic is associated with the Boom Telescope Extend Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 05" means that the ECM has determined that an open or a
short to ground exists in the circuit for the Boom Telescope Extend Solenoid.
● The power side of circuit (K760-PU) is open.
● The power side of circuit (K760-PU) is shorted to ground.
● The return side of the circuit (K761-GN) is open.
● The return side of the circuit (K761-GN) is shorted to ground.
● The Boom Telescope Extend Solenoid is faulty. The solenoid could have an open or a short to ground internally.
System Response
● The Boom Telescope Extend function will not work properly but Boom Telescope Retract function will work properly.
66
Test Step 1
2. Unplug the connector for the Boom Telescope Extend Solenoid.
Test Step 2
1. Disconnect the Boom Telescope Extend Solenoid.
● If the resistance of the Boom Telescope Extend Solenoid is less than or equal to 5 OHMS, then the solenoid has failed. Repeat ""Test Step 2" " in order to verify the solenoid failure.
After verification, replace the Boom Telescope Extend Solenoid and verify that the new solenoid fixes the problem.
Test Step 3
● If the resistance of the Boom Telescope Extend Solenoid is less than or equal to 5 OHMS, then go to ""Test Step 4" ".
● If the resistance is greater than 5 OHMS, then wire (K760-PU) is open. Repair the circuit or replace the jumper harness.
Test Step 4

● If the resistance is greater than 5 OHMS, then wire (K761-GN) is open. Repair the circuit or replace the jumper harness.
Test Step 5
● If the resistance is less than 5 OHMS, then wire (K760-PU) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 6
● If the resistance is less than 5k OHMS Wire (K761-GN) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 7
This diagnostic is associated with the Boom Telescope Retract Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 03" means that the ECM has determined that the voltage
is above normal.
● The energized side of circuit (K762-BU) is shorted to the battery. 69

● The return side of the circuit (K763-GY) is shorted to the battery.
System Response
Test Step 1
2. Unplug the rear hydraulic ECM and the Boom Telescope Retract Solenoid.
● If the resistance is less than 5k OHMS then wire (K762-BU) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 2
● If the resistance is less than 5k OHMS then wire (K763-GY) is shorted to the battery. Repair the circuit or replace the jumper harness.
Test Step 3

This diagnostic is associated with the Boom Telescope Retract Solenoid that is controlled by the Rear Hydraulic ECM. The "FMI 05" means that the ECM has determined that an open or a
short to ground exists in the circuit for the Boom Telescope Retract Solenoid.
● The power side of circuit (K762-BU) is open.
● The power side of circuit (K762-BU) is shorted to ground.
● The return side of the circuit (K763-GY) is open.
● The return side of the circuit (K763-GY) is shorted to ground. 71

● The Boom Telescope Retract Solenoid is faulty. The solenoid could have an open or a short to ground internally.
System Response
● The Boom Telescope Retract function and the Boom Telescope Extend function will not work properly.
Test Step 1
2. Unplug the connector for the Boom Telescope Retract Solenoid.
Test Step 2
1. Disconnect the Boom Telescope Retract Solenoid.
● If the resistance of the Boom Telescope Retract Solenoid is less than or equal to 5 OHMS, then the solenoid has failed. Repeat ""Test Step 2" " in order to verify the solenoid
failure. After verification, replace the Boom Telescope Retract Solenoid and verify that the new solenoid fixes the problem.
Test Step 3

● If the resistance of the Boom Telescope Retract Solenoid is less than or equal to 5 OHMS, then go to ""Test Step 4" ".
● If the resistance is greater than 5 OHMS, then wire (K762-BU) is open. Repair the circuit or replace the jumper harness.
Test Step 4
● If the resistance is greater than 5 OHMS, then wire (K763-GY) is open. Repair the circuit or replace the jumper harness.
Test Step 5
● If the resistance is less than 5 OHMS, then wire (K762-BU) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 6
73
● If the resistance is less than 5k OHMS Wire (K763-GY) is shorted to ground. Repair the circuit or replace the jumper harness.
Test Step 7
74

SI E 1001 Replacement 247-7829 Electronic Pilot Valve

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SPECIAL INSTRUCTION

Model Serial Number Range

TH330B TBG00100 & After

TH360B TBH00100 & After

TH560B TBP00100 & After

TH580B TBJ00100 & After

1 356-7326 Machine Software GP

Failure to relieve pressure before removing a load control valve or disassembling

Ensure all pressure is relieved before removing a load control valve or

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

(9) Wire (K762-BL) and wire (K763-GY)

(10) Wire (T973-WH) and wire (T974-BR)

(11) Wire (T975-PK) and wire (T978-GY)

(12) Wire (T971-OR) and wire (T972-GN)

(13) Wire (T969-YL) and wire (T970-GY)

(14) Wire (E891-WH) and wire (E892-PK)

(15) Wire (E893-BR) and wire (E894-OR)

❍ Wire (K760-PU) and wire (K761-GR) are in connector (8) .

❍ Wire (K762-BL) and wire (K763-GY) are in connector (9) .

❍ Wire (T975-PK) and wire (T978-GY) are in connector (11) .

❍ Wire (T971-OR) and wire (T972-GN) are in connector (12) .

❍ Wire (T969-YL) and wire (T970-GY) are in connector (13) .

❍ Wire (E891-WH) and wire (E892-PK) are in connector (14) .

❍ Wire (E893-BR) and wire (E894-OR) are in connector (15) .

Instructions for Flashing Software on the Rear Hydraulic ECM

2. Wait for "WinFlash" in order to connect to the ECM.

3. Select the "Implement Control" ECM.

5. Select the "Begin Flash" option.

Instructions for Updating the Master Implement ECM Software

2. Once Cat ET has connected, select the "Main Control ECM".

4. Select "Machine Control Module".

Diagnostic Code MID 039-CID 1138 - FMI 03

● The energized side of circuit (E893-BR) is shorted to the battery.

● The return side of the circuit (E894-OR) is shorted to the battery.

● All functions are disabled.

1. Ensure that the key for the machine is off.

3. Measure continuity between X1 and all power sources. 31

1. Measure the continuity between Y1 and all power sources.

Expected Test Results From Test Step 2

2. Reconnect all of the harness connectors.

4. Operate the machine.

5. Check the status of the CID 1138 FMI 03 diagnostic code.

Expected Test Results From Test Step 3

Diagnostic Code MID 039-CID 1138 - FMI 05

● The power side of circuit (E893-BR) is open.

● The power side of circuit (E893-BR) is shorted to ground.

● The return side of the circuit (E894-OR) is open.

● The return side of the circuit (E894-OR) is shorted to ground.

2. Unplug the connector for the Boom Retract Solenoid.

3. Measure continuity between X1 and Y1.

Expected Test Results From Test Step 1

● If the resistance is not in the range, go to ""Test Step 2" ".

1. Disconnect the Boom Retract Solenoid.

2. Place a suitable jumper wire between X2 and Y2.

3. Measure the continuity between X1 and Y1.

Expected Test Results From Test Step 2

1. Remove the jumper wire that is between X2 and Y2.

2. Measure the continuity between X1 and X2.

Expected Test Results From Test Step 3

1. Verify that the jumper wire between X2 and Y2 is removed.

2. Measure continuity between Y1 and Y2. 34